Description
Film Heaters for Aerospace Application description
Condition:New
Power Source:Electric
Place of Origin:Guangdong, China
Brand Name:HengXin or Customized
Dimension(L*W*H):Customized
Voltage:3.7-220V
Warranty:40K working hours
Working Temperature Range:-30 –180℃
Material:Polyimide film+etched metal foil
Size:Customized custom,Max 300*1400mm,mini 10*10/3*280mm
Thickness:0.18-0.226mm
Back adhesive:3M 467 / 468 or customized
Power deviation:5%-10%
Supply Ability:100,000 Piece/Pieces per Week
Certificates:ISO9001
Packaging Details:PE inner bag+Carton
Advanced Film Heaters for Aerospace Applications: Lightweight Thermal Precision at Its Best
In the ever-evolving aerospace industry, technology must strike a delicate balance between performance, reliability, and weight. As spacecraft, satellites, drones, and high-altitude aircraft continue to push boundaries, so too must the thermal solutions that protect their sensitive components. This is where film heaters—especially polyimide and silicone rubber film heaters—shine. These ultra-thin, flexible heating elements are rapidly becoming the go-to thermal management solution for aerospace engineers worldwide.
In this article, we explore why film heaters are ideal for aerospace applications, the benefits they offer, typical use cases, and how HENGXIN TECHNOLOGY delivers custom-engineered heaters to meet the most demanding requirements.
What Are Film Heaters?
Film heaters, also known as flexible thin-film heaters, are lightweight heating elements made by embedding a resistive circuit (etched foil or wire-wound) between two insulating layers such as polyimide (PI) or silicone rubber. When powered by electricity, the circuit generates heat that is uniformly distributed across the surface.
The compact form factor and high thermal efficiency make these heaters ideal for applications where space is limited and precision is crucial—like in aerospace.
Why Are Film Heaters Essential in Aerospace?
The aerospace environment is one of extremes—extreme cold at high altitudes or in orbit, rapid temperature fluctuations, and strict weight constraints. Traditional heating methods such as bulky cartridge heaters or radiant heat lamps are not suitable for these scenarios.
Here’s why film heaters are preferred in aerospace thermal control systems:
1. Ultra-Lightweight and Thin
Every gram counts in aerospace. Film heaters can be as thin as 0.13 mm and weigh a fraction of conventional heating systems. This allows engineers to integrate heating directly into structural components without affecting mass or aerodynamics.
2. Flexible and Custom-Fit
Whether it’s a curved avionics panel, cylindrical fuel line, or irregular satellite enclosure, film heaters can be custom-shaped to fit complex geometries. They offer uniform adhesion and surface contact, which is critical for efficient heat transfer.
3. High Reliability in Harsh Conditions
Polyimide film heaters can withstand temperatures ranging from -60°C to +200°C, and they maintain stable resistance even in vacuum, high humidity, and radiation-prone environments. This makes them suitable for both atmospheric flight and space missions.
4. Precise Temperature Control
With integrated digital or analog thermostats, thermistors, and thermal fuses, film heaters allow precise thermal regulation. This is vital for protecting temperature-sensitive avionics, batteries, and payloads from malfunction.
5. Energy Efficiency
Low thermal mass and close contact with heated surfaces mean quicker warm-up times and minimal energy loss—ideal for power-limited systems like satellites and UAVs.
Materials Used in Aerospace Film Heaters
Two primary materials dominate aerospace film heater construction:
➤ Polyimide (Kapton®) Heaters
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Extremely thin, strong, and flexible
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Excellent dielectric properties
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Resistant to chemicals and radiation
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Commonly used in satellites, telescopes, and avionics
Technical Specifications:
| Feature | Details |
|---|---|
| Thickness | 0.13mm–0.3mm |
| Voltage Range | 3V to 240V (customizable) |
| Power Density | Up to 5 W/cm² |
| Temperature Range | -60°C to +200°C |
| Heating Element | Etched copper or nickel-chrome foil |
| Insulation Material | Polyimide film (Kapton® equivalent) |
| Adhesives | Optional PSA (pressure-sensitive adhesive) |
| Sensors | NTC, RTD, thermocouples (optional) |
| Certifications | RoHS, UL, ISO9001 manufacturing available |
Key Advantages of Ultra Thin Polyimide Film Heaters
✅ Ultra Thin & Flexible
At under half a millimeter thick, polyimide heaters can conform to curved, uneven, or moving surfaces. This makes them ideal for aerospace instruments, wearables, or robotics.
✅ Uniform & Rapid Heating
The precision-etched foil ensures even heat distribution and faster ramp-up times compared to traditional wire-wound or silicone heaters.
✅ Chemically Resistant & Durable
Polyimide withstands oil, solvents, acids, radiation, and vacuum environments, making it the preferred solution in cleanroom or aerospace settings.
✅ Wide Operating Range
Stable at extreme temperatures from cryogenic (-200°C) to high heat (+200°C), perfect for demanding applications like satellites, lab devices, and thermal testing.
✅ Lightweight & Energy Efficient
Minimal thermal mass reduces energy consumption and improves system efficiency. Perfect for portable or battery-powered devices.
Common Aerospace Applications of Film Heaters
The adaptability of film heaters enables their use in a wide variety of aerospace systems. Below are some high-impact applications:
🔹 Avionics Heating
Film heaters prevent condensation inside control units, sensors, and instrument panels, ensuring reliable function during takeoff and in-flight operation.
🔹 Battery Thermal Management
In UAVs, satellites, and aircraft, maintaining optimal battery temperature extends life and ensures consistent power delivery. Film heaters wrap around battery packs for safe, uniform warming.
🔹 Fuel Line and Valve De-Icing
Film heaters can be applied to fuel systems and valves to prevent freezing at high altitudes. The heaters are controlled automatically via thermostats or integrated controllers.
🔹 Satellite Payload Protection
Temperature-sensitive payloads like cameras, sensors, and electronics require tight thermal regulation. Polyimide heaters are widely used in orbit to combat the extreme cold of space.
🔹 Antenna & Sensor Heating
For high-performance radars, sensors, and communication systems, film heaters maintain functionality by keeping components above their minimum operating temperature.
🔹 Optical Equipment Heating
In astronomy and aerospace optics, heaters prevent fogging and thermal distortion in telescopes and cameras, enhancing clarity and reliability.
Request a Quote or Free Consultation
Looking to integrate an ultra thin polyimide film heater into your design? We’ll help you customize the perfect heater for your project — whether you’re in aerospace, healthcare, or high-end electronics.
👉 Contact us today to get a free consultation, datasheet, or sample.
Polyimide Film Heater in different shapes
Polyimide Film Heater Application
Our Factory
ShenZhen ZhuoYue HengXin Technology Development Co.,Ltd Is a company specializing in the production of electric film heaters.
We started as a family workshop in 1988, and now have developed into a professional film heater supplier integrating development, design, production and sales. Our main products are Polyester Film Heater, PET Film Heater, Polyimide Film Heater, Graphene Film Heater, Kapton Film Heater and Silicone Rubber Heater. We have passed the ISO9001 certification and maintain good cooperative relationships with domestic and foreign customers. The product quality is guaranteed and the price is advantageous. Welcome customers worldwide to inquire our products and audit our factory. We look forward to cooperating with you for a win-win situation!
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Certificates of the Film Heaters
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